report draft din 19523 - rausch electronics usa, llc project: jetting restistance test according to...

Report

Project: Jetting restistance test according to draft DIN-standard 19523, August 2007

Product: Quick-Lock-System Client: Uhrig Kanaltechnik GmbH Am Roten Kreuz 2 78187 Geisingen Contractor: IRO GmbH Oldenburg Ofener Straße 18 26121 Oldenburg date: 18.04.2008 mangager: Prof. Dipl.-Ing. Th. Wegener competent official: Dipl.-Ing. M. Böge

iro GmbH Oldenburg page 1

Jetting resistance test

according to

Draft DIN-standard 19523, August 2007

Report

Contents

1 Theme............................................................................................................. 2

2 Test specimen................................................................................................. 2

3 Test conditions ................................................................................................ 6

3.1 Material test method................................................................................. 6

3.2 Practical test method................................................................................ 8

4 Test ............................................................................................................... 10

5 Material test method on beaded gasket ........................................................ 12

6 Results .......................................................................................................... 13

7 Literature ....................................................................................................... 14

8 Annex............................................................................................................ 14


1 Theme

The „Quick-Lock“– system of the company Uhrig Kanaltechnik GmbH, as one of

the mounting system for internal pipe rehabilitations, has been tested against high

pressure clean water jetting by iro GmbH Oldenburg.

The draft of the DIN-standard 19523 specifies a test method for the resistance to

high pressure clean water jetting of pipes systems. The test method was applied to

the „Quick-Lock“– system.

In principle the mechanical load resulting from the high pressure water jet can

negatively influence the function of a rehabilitation product. Therefore the focus

was laid on the displace security and water tightness of the system during the

tests.

In addition the test assemblies should be placed for usual damages which can oc-

cur on sewer or other pipe system made of vitrified clay or concrete. For that the

conditions of the defected pipe system should be as realistic as possible.

The water tightness of the rehabilitated system was proofed by a watertight - test

method described in DIN EN-standard 1610.

2 Test specimen

The test specimen is a stainless steel gasket with an integral mechanical lock sys-

tem – the so called „Quick-Lock”-gasket from type „standard“.

The water tightness and place security is achieved by an EPDM- compression

sealing, which fits closely to the inner pipe after expanding the gasket.

Dates of test assembles:

Producer UHRIG Kanaltechnik

Name of product „Quick-Lock“-System“ - type standard

Diameter DN 300

Wall thickness 1.2 mm

Length 400 mm


The „Quick-Lock“-gaskets are usually qualified for partial rehabilitating of damaged

pipe systems. The damages are confined to “condition I and II”. Both are defined

in dwa-sheet M 127-2. Mainly of the described damages on pipes are leaks

caused by cracks, occurrence of fragments and lost pieces.

The test range was committed as following shown:

A 1.00 m section of vitrified clay pipe was used for the material test. Here a

„Quick-Lock“- gasket was placed on a cross-cracked part of the pipe.

Fig. 1: section of vitrified clay pipe with cross-crack (outer face)

Fig. 2: section of vitrified clay pipe with placed gasket (inner face)

For carrying out the practical test two 10 m long test courses of vitrified clay and

concrete pipe sections (DN 300) were built over ground. The simulated damages

were created by iro as shown by the following:


Damage de-

scription

Vitrified clay pipe Concrete pipe

1 Fragments

2 Cross-crack Not taken in consideration

3 Longitudinal

crack

Not taken in consideration

4 Broken seal-

ing in joint

section

5 Lost piece /

failed connec-

tion


For creating the cracks the definitions of condition II according to dwa sheet M 127

– 2 were observed. Therefore the crack-width resulted from the defined pipe de-

formation.

Beyond it the length of the fragments has to be longer than a gasket is (40 cm).

Such damages usually are rehabilitated by the use of successively placed gas-

kets.


3 Test conditions

As described below the tests were carried out under consideration of specifically

test parameters and test conditions.

3.1 Material test method

A high pressure water jet is directed at a specified angle to and distance from the

test surface. It is moved relative and parallel to the inner surface of the test speci-

men. The resulting mechanical load (expressed as jet power density) is kept within

specified limits for the duration of the test by controlling the parameters water

pressure, flow rate, distance and jet spread angle.

nominal test parameters for the material method:

Water quality Freshwater

Temperature of water and air 15°C ±10°C

Jet power density Dj 450 W/mm2

Jet spread angle ω ≤ 3.3 °

Nozzle angle α 30° ± 1°

Vertical distance between the

test surface and the centre of

the nozzle orifice

(10 + 0.00 – 2.00) mm

Orifice diameter of the nozzle

insert

(2.50 ± 0.02) mm

Amount of test courses 3 with a distance t.a. of 10 cm

Length of test courses usually 1.00 m + 2 x 150 mm accelerating

length (here: length of gasket + 100 mm for

testing the edge of the gasket)

Velocity of travel (0.2 ± 0.02) m/min.

Test procedure per test course 3 test cycles (forwards/backwards)


All dimensions of the nozzle shall conform to figure 3.

fig 3: nozzle Ø 2,5 mm for material test method according to draft DIN-standard 19523

The nozzle shall have a wear-resistant ceramic insert.


3.2 Practical test method

This test method considers the mechanical loads during the high pressure clean

water jetting resulted from the high water jet itself and additionally the weight of the

nozzle and hose.

According to the draft DIN-Standard 19523 the test course shall have a length of

at least 15 m with a gradient of 0 ‰ – 3 ‰. In contrast to this requirement the

„Quick-Lock”- gaskets were built in the two test courses described in chapter 2.

Nominal test parameters for the material method:

Water quality Freshwater

Temperature of water and air 15°C ±10°C

Jet power density Dj 330 W/mm2

Test nozzle Standard-nozzle (fig. 4)

Nozzle angle α 30° ± 1°

Amount of nozzle insert 8

Orifice diameter of the nozzle

insert

(2.60 ± 0.02) mm

Length of test courses usually 15 m (here description in chapter 2)

Velocity of travel – feed (1.0 ± 0.1) m/s

Velocity of travel – retreat (0.1± 0.02) m/s

Test procedure 60 test cycles (forwards/backwards)


All dimensions of the nozzle and inserts shall conform to figure 4.

Parameter Value

Length of nozzle (17 +- 0.5) cm

Weight of nozzle (4.5 +- 0.1) kg

Diameter of nozzle (8+- 0.5) cm

fig 4: standard-nozzle for practical test method according to draft DIN-standard 19523

The nozzle shall have wear-resistant ceramic inserts.


4 Test

The material test on the test specimen was carried out on February, 5th 2008 at

the testing ground of iro GmbH Oldenburg.

After placing the gasket the test specimen had no visual damages and could now

be tested.

Fig. 5: test specimen with placed gasket installed in test-stand

During the material test the water jet forced through the sealing and came out of

the pre-damaged pipe-wall (fig. 5).

After the test there were no visual damages on the gasket. Beyond it the water

tightness of the system was proved according to the air test method described in

DIN EN –standard 1610 [2].

The practical test on the two test course was carried out on January, 17th and 21st

2008 at the testing ground of iro GmbH Oldenburg.

(fig. 6 + 7).

The test courses described in chapter 2 had no visual damages and could now be

tested.


Fig. 6: practical testing of the Quick-Lock-System in vitrified clay pipe (inside)

fig 7: practical testing of the Quick-Lock-System in concrete pipe (outside)

During the material test the area around the cross-crack at the concrete pipe was

conspicuous. In the development of the test an increasing amount of water estab-

lished which came out of the pre-damaged pipe-wall.

After the test there were visual deformations on two of the gasket-edges placed in

the vitrified clay pipes. The cause of these deformations is obviously a mechanical

hitch of the nozzle during the retreat-process. During the water tightness-test with

0,5 bar according DIN EN –standard 1610 [2] one of the gaskets which was placed

at the cross-cracked concrete-pipe failed.

After replacing the gasket which failed the jetting test was repeated in this section

of the test-course with the following proofs of failures.

The repeated investigations on the gasket system had shown no further failures.


5 Material test method on beaded gasket

In addition to the described tests the material test method was applied on a further

developed gasket of the company Uhrig Kanaltechnik GmbH.

The difference to the „standard“-gasket described in chapter 2 is a beaded edge

placed in flow and cleaning direction.

Analogous the material test was carried out like the test described in Chapter 3.1

(fig.8).

Fig. 8: test assembly with beaded gasket installed in test-stand

Compared to the test-results of the „standard“-gasket the beaded gasket pre-

vented the forcing of the water jet through the sealing. During the test the gasket

obviously stayed tight.

After the test there were no visual damages on the gasket. Beyond it the water

tightness of the system was proved according to the air test method described in

DIN EN –standard 1610 [2].


6 Results

The résumé of the tests shows that the tested rehabilitation method „Quick-Lock“-

gasket of the company Uhrig Kanaltechnik GmbH has withstood the test condi-

tions according the draft of DIN-standard 19523, August 2007. The draft of the

standard defines the requirements on test conditions to test the behaviour of

sewer or parts of it during the high pressure clean water jetting.

An additional material test on a further developed gasket had shown a positive

effect. During the jetting cleaning the beaded edge of the gasket prevented the

water jet from forcing through the sealing. Besides the risk of a possible nozzle

hick during the retreat could be minimised.

Oldenburg,

April, 8th 2008

Prof. Dipl.-Ing. Thomas Wegener Dipl.-Ing. Mike Böge

Geschäftsführer Sachbearbeiter


7 Literature

[1] DIN 19523 – Norm-Entwurf, Anforderungen und Prüfverfahren zur Ermittlung

der Hochdruckstrahlbeständigkeit und -spülfestigkeit von Rohrleitungsteilen für

Abwasserleitungen und -kanäle, August 2007

[2] DIN EN 1610, Verlegung und Prüfung von Abwasserleitungen und –kanälen,

Oktober 1997

8 Annex

1. Prüfprotokoll mit Fotodokumentation der Werkstoffprüfung nach Norm-

Entwurf DIN 19523, August 2007

1-1 Quick-Lock-Standard

1-2 Quick-Lock Aufbördelung

2. Prüfprotokoll mit Fotodokumentation der Praxisprüfung nach Norm-

Entwurf DIN 19523, August 2007

3. Kanalfernsehprotokoll, Fa. Kleen GmbH, Norden

Anhang 1-1 Protokoll Werkstoffprüfung gemäß DIN-Entwurf 19523, August 2007

1

Projekt: G 35.560 Prüfdatum: 21.01.08 Prüfer: MBö Hersteller: Uhrig Kanaltechnik GmbH Bezeichnung: Quick-Lock-System Kennzeichnung des Prüfstücks: QL-Standard/STZ

Abbildung 1: Prüfstück während der Werkstoffprüfung

Prüfparameter: Vertikaler Abstand zwischen der Prüfoberfläche und der Mitte des Düseneinsatzes 10 mm -2mm Strahlwinkel α: 30° +/- 1° Düseneinsatz- Ø d vor und nach Prüfung: 2,50 +/-0,02 mm Prüfgeschwindigkeit: 0,2 +/- 0,02 m /min Anzahl der Prüfzyklen: 3 x 3 Zyklen Umgebungstemperatur 7 °C Wassertemperatur 15 °C Ausbreitungswinkel des Spülstrahls ω: < 3,3° cd – Wert vor der Prüfung 0,899 cd – Wert nach der Prüfung 0,900 Durchschnittliche Spülstrahl-Leistungsdichte DJ für Prüfstrecke 1 451 W/mm

2

Prüfstrecke 2 446 W/mm2



2

Ergebnisse

Schadensdokumentation: Oberflächenbeschaffenheit des Prüfstücks vor der Prüfung

- Glatt, keine Auffälligkeiten

Oberflächenbeschaffenheit des Prüfstücks nach der Prüfung

- Die Manschette weist nach der Prüfung keine Schäden infolge des HD-Spülstrahls auf.


3

Fotodokumentation

Abbildung 2: Prüfstück nach der Prüfung


1

Projekt: G 35.560 Prüfdatum: 21.01.08 Prüfer: MBö Hersteller: Uhrig Kanaltechnik GmbH Bezeichnung: Quick-Lock-System Kennzeichnung des Prüfstücks: QL-Aufbördelung/STZ

Abbildung 1: Prüfstück während der Werkstoffprüfung

Prüfparameter: Vertikaler Abstand zwischen der Prüfoberfläche und der Mitte des Düseneinsatzes 10 mm -2mm Strahlwinkel α: 30° +/- 1° Düseneinsatz- Ø d vor und nach Prüfung: 2,50 +/-0,02 mm Prüfgeschwindigkeit: 0,2 +/- 0,02 m /min Anzahl der Prüfzyklen: 3 x 3 Zyklen Umgebungstemperatur 7 °C Wassertemperatur 15 °C Ausbreitungswinkel des Spülstrahls ω: < 3,3° cd – Wert vor der Prüfung 0,889 cd – Wert nach der Prüfung 0,895 Durchschnittliche Spülstrahl-Leistungsdichte DJ für Prüfstrecke 1 450 W/mm

2




2

Ergebnisse

Schadensdokumentation: Oberflächenbeschaffenheit des Prüfstücks vor der Prüfung


Oberflächenbeschaffenheit des Prüfstücks nach der Prüfung

- Die Manschette weist nach der Prüfung keine Schäden infolge des HD-Spülstrahls auf.


3

Fotodokumentation

Abbildung 2: Prüfstück nach der Prüfung

Anhang 2 Protokoll Praxisprüfung gemäß Entwurf DIN 19523, August 2007

1

Projekt: G 35.560 Prüfdatum: 17. + 21.01.2008 Prüfer: MBö Hersteller: Uhrig Kanaltechnik GmbH Bezeichnung: Quick-Lock-System Kennzeichnung der Prüfstrecke: QL Steinzeug / Beton Aufbau der Versuchsstrecken:

Siehe „Kanalfernsehprotokolle“ der Fa. Kleen GmbH, Norden

Düsenkörper: Düsenlänge: 17 +/- 0,5 cm Düsengewicht: 4,5 +/- 0,1 kg Düsenkörperdurchmesser: 8 +/- 0,5 cm

Prüfparameter: Durchfluss Q: 280 – 285 l/min Strahlwinkel α: 30° +/- 1° Düseneinsatz- Ø d

vor und nach Prüfung: 2,60 +/-0,02 mm

Vorschubgeschwindigkeit: 1,0 +/- 0,1 m/s Rückzuggeschwindigkeit: 0,1 +/- 0,02 m/s Anzahl der Prüfzyklen: 60 Umgebungstemperatur 9 °C Wassertemperatur 12° C Druck vor der Prüfung bei 282,5 l/min 104,2 bar Druck nach der Prüfung bei 282,5 l/min 105,9 bar cd – Wert vor der Prüfung 0,761 cd – Wert nach der Prüfung 0,757 Durchschnittliche Spülstrahl-Leistungsdichte DJ 332 W/mm

2


2

Ergebnisse

Schadensdokumentation: Oberflächenbeschaffenheit der Manschetten vor der Prüfung


Oberflächenbeschaffenheit der Manschetten nach der Prüfung

- Die Innenoberfläche der Manschetten weist nach der Prüfung im Sohlbereich Schlauchabriebspuren auf.

- Zwei Manschetten im Steinzeugrohr weisen nach der Prüfung am Rand leichte Verformungen infolge mechanischen Düsenwiderstandes auf.


3

Fotodokumentation

Abbildung 1: Schlauchabrieb im Sohlbereich nach der Prüfung


4

Abbildung 2: Deformation des Manschettenrandes nach der Prüfung

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